Air filter element assembly for a motor vehicle

ABSTRACT

A filter element assembly includes a filter body and an auxiliary filter. The filter body includes a sidewall around a hollow core. Further the filter body and auxiliary filter are both received and held on a support including a base and a cage.

TECHNICAL FIELD

This document relates generally to the motor vehicle equipment fieldand, more particularly, to a filter element assembly incorporating aprimary filter and an auxiliary filter.

BACKGROUND

An internal combustion engine of a vehicle requires an adequate supplyof filtered, fresh air to function properly. Accordingly, air from theatmosphere may be drawn through a particle filter to remove dust andother particulates before the air enters the air intake of the engine.For vehicles operating in temperate climates, a single particle filtermay provide many months of adequate air filtration before the filterbecomes clogged and a replacement is needed. During severe weatherconditions, however, the filter may clog prematurely with ice and snow,thereby restricting air flow into the engine and degrading engineperformance. Such severe weather conditions may include, for example,very snowy conditions.

One solution to this problem is to install a specialized grille cover onthe vehicle to prevent entry of snow and/or dust into an air filtrationsystem of the vehicle. However, such grille covers are matchedspecifically to the front-end configuration of the vehicle on which itis installed and may, therefore, be expensive to produce. Furthermore,the vehicle operator may have to install and remove the grille coverrepeatedly in response to changing weather conditions, causingdissatisfaction.

It is known to provide air filtration systems adapted to supplysufficient clean air to the intake of the engine when the air filtrationsystem becomes clogged or blocked. Such air filtration systems maycomprise a housing that is configured to partition a filter into a mainportion and an auxiliary portion, wherein an auxiliary air inlet may beconfigured to direct air to the auxiliary portion of the filter upon themain portion of the filter becoming blocked.

However, air filtration systems adapted for operation in severe weatherconditions may be more expensive and more difficult to service than astandard air filtration system configured for use in cold temperateclimates. The present invention seeks to address these issues.

SUMMARY

In accordance with the purposes and benefits described herein, a filterelement assembly is provided for a motor vehicle. That filter elementassembly comprises a support, a filter body carried on the support andan auxiliary filter. The filter body includes a sidewall around a hollowcore. In one possible embodiment the filter body forms an ellipticcylinder. In one possible embodiment the filter body is a pleat-packfilter.

In one possible embodiment, the auxiliary filter is an open cell foam.In one possible embodiment, the auxiliary filter is carried on thesupport outside of the core. In one possible embodiment, the filter bodyhas a first longitudinal axis and the auxiliary filter has a secondlongitudinal axis wherein the first longitudinal axis is parallel to andoffset from the second longitudinal axis. In one possible embodiment thefilter element assembly further includes a sealing ring on the filterbody around the axial outlet.

In one possible embodiment, the support includes a base and a cage. Thefilter body is received on the base around the cage. The support furtherincludes an auxiliary filter mount that receives and holds the auxiliaryfilter. The mount includes two partitions that divide the filter bodyinto a first section that functions as the primary filter and a secondsection that is downstream from the auxiliary filter. The partitions arereceived in valleys between pleats of the pleat-pack filter.

Still further, the auxiliary filter includes a mounting groove and themount includes a u-shaped wall received in that mounting groove whichalso could be formed fully enclosed. A fastener received in the twopartitions and the mounting groove secures the auxiliary filter to thesupport.

In the following description, there are shown and described severalpreferred embodiments of the filter element assembly. As it should berealized, the filter element assembly is capable of other, differentembodiments and its several details are capable of modification invarious, obvious aspects all without departing from the assembly as setforth and described in the following claims. Accordingly, the drawingsand descriptions should be regarded as illustrative in nature and not asrestrictive.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The accompanying drawing figures incorporated herein and forming a partof the specification, illustrate several aspects of the filter elementassembly and together with the description serve to explain certainprinciples thereof. In the drawing:

FIG. 1 is a side elevational view of the filter element assembly showingboth the primary filter and the auxiliary filter.

FIG. 2 is a perspective view of the filter element assembly lookingdownwardly into the core through the axial outlet and showing thesupport.

FIG. 3 is a perspective view of the support.

FIG. 4 is a top plan and partially broken-away view illustrating thefilter element assembly of FIGS. 1 and 2 positioned in the air cleanerbox of the air cleaner assembly of a motor vehicle and showing how thepartitions divide the filter body into two sections.

FIG. 5 is a perspective view of the air cleaner assembly illustrating inthe inlet duct leading to and the outlet duct leading from the aircleaner box.

FIG. 6 is a detailed side elevational view illustrating the inlet ductopening in the side of the air cleaner box.

FIG. 7 is a top plan view illustrating the lid closes the top of the aircleaner box and incorporates an outlet plenum and the outlet duct.

Reference will now be made in detail to the present preferredembodiments of the filter element assembly, examples of which areillustrated in the accompanying drawing figures.

DETAILED DESCRIPTION

Reference is now made to FIGS. 1 and 2 illustrating the filter elementassembly 10 which includes a filter body 12 and an auxiliary filter 14.As illustrated in FIGS. 1 and 2, the filter body 12 has a firstlongitudinal axis A₁ while the auxiliary filter 14 has a secondlongitudinal axis A₂. In the illustrated embodiment the firstlongitudinal axis A₁ is parallel to and offset from the secondlongitudinal axis A₂. The filter body 12 comprises a sidewall 16 and ahollow core 18. In the illustrated embodiment, the sidewall 16 is formedby a pleat-pack of pleated filter media of a type known in the art.

As should be appreciated, both the filter body 12 and auxiliary filter14 are received and held on a support 20. As best illustrated in FIG. 3,support 20 includes a base 22 and a cage 24 which both may be integrallymolded as one or created as separate parts secured together. The filterbody 12 is received on the base 22 around the cage 24 so that the cageprojects into the hollow core 18 (see FIG. 2). An adhesive may be usedto secure the filter body 12 to the base 22. The cage 24 supports thefilter 12 and prevents it from collapsing inwardly as air is drawnthrough the filter body 12 by the motor of the vehicle.

As should be further appreciated, the base 22 closes a first end of thecore 18. In contrast, the second end of the core 18 remains open,forming an axial outlet 30 as will be described in greater detail below.A pleat sealing ring 32 of polyurethane or other appropriate materialengages the end of the sidewall 16 and extends around the axial outlet30. In the illustrated embodiment, the filter body 12 is oval incross-section and forms an elliptic cylinder.

The auxiliary filter 14 is formed from an open cell foam filteringmaterial such as a polyester foam or a reticulated open cell polyetherfoam. The foam of the auxiliary filter 14 provides a more restrictedairflow then the filter media of the filter body 12. In one possibleembodiment the foam provides approximately in excess of two inches ofmercury restriction.

As should be appreciated, the inner face 36 of the auxiliary filter 14is arcuate and includes a radius of curvature substantially matching theradius of curvature of the outer wall of the filter body 12.Accordingly, the auxiliary filter 14 may be carried against the filterbody 12 outside the core 18. As further shown in FIG. 3, the support 20includes two partitions 38, 40, an auxiliary filter mount in the form ofa curved, u-shaped wall 42 and a curved strip fastener 44. In analternative embodiment not shown, the fastener 44 may be straight. Theauxiliary filter 14 includes a mounting groove 46 (see FIG. 2). Theauxiliary filter 14 is positioned over the u-shaped wall 42 so that thewall is received in the groove 46 and the filter extends through theopening 48 in the wall. The fastener 44 is then inserted into the top ofthe groove 46 and the cooperating slots 50 in the partitions 38, 40 tocomplete the connection and hold the auxiliary filter 14 in position onthe support against the filter body 12. This facilitates assembly of theauxiliary filter foam 14 to the support 20.

As best illustrated in FIG. 4, the partitions 38, 40 are received invalleys 52 between pleats 54 of the pleat-pack filter body 12. Thepartitions 38, 40 extend uninterrupted from the base 22 to the sealingring 32 and effectively function to divide the filter body 12 into afirst section 56 that functions as a primary filter and a second section58 downstream from the auxiliary filter 14. As will be explained ingreater detail below, during normal operation, air is drawn into theengine through the first section 56 of the filter body 12 (note actionarrows A in FIG. 4). The greater resistance to air flow of the auxiliaryfilter 14 and the partitions 38, 40 substantially prevent any air flowthrough the second section 58. However, should the first section 56become sufficiently clogged so that the air flow resistance of the firstsection rises above that of the auxiliary filter 14, air will be drawnthrough the auxiliary filter and the second section 58 (note actionarrow B).

FIG. 4 also illustrates the positioning of the filter element assembly10 in the air cleaner box 60 of a vehicle air cleaner assembly generallydesignated by reference numeral 62. More specifically, FIG. 4illustrates the air cleaner box 60 with the lid 64 removed. As should beappreciated, the filter element assembly 10 may be easily installedwithin the air cleaner box 60. More specifically, the filter elementassembly 10 inclusive of the integrated filter body 12 and auxiliaryfilter 14 is simply inserted into the air cleaner box 60 with theauxiliary filter 14 oriented into the corner 66 of matching shape sothat the outer face of the auxiliary filter 14 fits flush or withdesigned interference in the corner. As illustrated in FIG. 6, whenfully seated in position, the base 22 of the support 20 rests on theprojections 68 extending upwardly from the bottom wall 70 of the aircleaner box so as to provide an air passageway between the base and thebottom wall.

As illustrated in FIGS. 5-7, the air cleaner assembly 62 also includesan inlet duct 72 for directing air into the air cleaner box 60 throughthe opening 74 in the bottom wall 70 and sidewall 76 thereof. Further,the filter element assembly 62 includes the lid 64 that closes the topof the air cleaner box 60 after the filter element assembly 10 has beenseated therein. The clips 78 hold the lid 64 in position. As should befurther appreciated, the lid 64 includes an outlet plenum 80 and anoutlet duct 82. As should be appreciated, the outlet plenum 80 is formedin the lid 64 with an oval shaped opening that is aligned with andmatches the axial outlet 30 of the filter element assembly 10. Whenproperly seated and fixed in position by the clips 78, the lid 64provides a radial and/or axial seal that extends around the axial outlet30 thereby providing a sealed pathway from the core 18 of the filterelement assembly 10 through the outlet plenum 80 to the outlet duct 82.

During normal engine operation, air is drawn into the engine through theinlet duct 72 and the opening 74 into the air cleaner box 60. Air isthen drawn through the first section 56 of the filter body 12 whichcaptures dust and particulates. The clean air drawn into the core 18then passes through the axial outlet 30 into the outlet plenum 80 andthen from the outlet duct 82 to the engine of the vehicle. It should beappreciated that during normal operation, the air passes substantiallyexclusively through first section 56 of the filter body 12 which has farless resistance to airflow than the open cell foam of the auxiliaryfilter 14. As a result, the second section 58 of the filter body 12remains clean and clear of any particulates or other material whichmight degrade its performance.

In the event airflow through the primary filter 12 becomes morerestricted than the auxiliary filter 14 such as due to ingestion of iceor snow during inclement weather conditions, air will automatically bedrawn from the engine compartment of the vehicle through the auxiliaryfilter by way of the opening 84 in the side wall of the air cleaner box60 at the corner 66 (see FIG. 7). As should be appreciated, air in theengine compartment has been warmed by the engine. Accordingly, theauxiliary filter 14 and the second section 58 of the filter body 12downstream thereof remain free and clear of snow and ice particles.Thus, the airstream being drawn through the auxiliary filter 14 remainsavailable even in inclement weather conditions. That airstream passesfrom the auxiliary filter 14, to the second filter body section 58between, the partitions 38, 40 and then through the core 18, the axialoutlet 30, the outlet plenum 80 and the outlet duct 82 to the engine.Thus, the engine receives the necessary air to remain running until thevehicle reaches a service area.

In summary, the filter element assembly 10 provides a number ofbenefits. More specifically, the filter element assembly 10 includes anintegrated filter body 12 and auxiliary filter 14 which allows thefilter element assembly 10 to be quickly and easily installed in the aircleaner box 60 of the vehicle filter element assembly 62 even out in thefield. The filter element assembly 10 is also characterized byinexpensive manufacturing costs.

The foregoing has been presented for purposes of illustration anddescription. It is not intended to be exhaustive or to limit theembodiments to the precise form disclosed. Obvious modifications andvariations are possible in light of the above teachings. For example, inone possible embodiment the second section 58 of the filter body 12 iseliminated and an open passageway is provided downstream of theauxiliary filter 14 between the partitions 38, 40. In another possibleembodiment, the leading edge of the partitions 38, 40 extending into thepleat valleys 52 may include a soft edge of polyurethane, rubber orother appropriate material so as to be less abrasive as the pleats 54vibrate during vehicle operation. All such modifications and variationsare within the scope of the appended claims when interpreted inaccordance with the breadth to which they are fairly, legally andequitably entitled.

What is claimed:
 1. An filter element assembly for a motor vehiclecomprising: a support; a filter body carried on said support, saidfilter body including a sidewall around a hollow core; and an auxiliaryfilter carried on said support.
 2. The filter element assembly of claim1, wherein said filter body forms an elliptic cylinder.
 3. The filterelement assembly of claim 2, wherein a first end of said core is closedby said support and a second end of said core is an axial outlet.
 4. Thefilter element assembly of claim 3, wherein said filter body is apleat-pack filter.
 5. The filter element assembly of claim 4, whereinsaid auxiliary filter is an open cell foam.
 6. The filter elementassembly of claim 5, wherein said auxiliary filter is carried on saidsupport outside said core.
 7. The filter element assembly of claim 6,wherein said filter body has a first longitudinal axis and saidauxiliary filter has a second longitudinal axis wherein said firstlongitudinal axis is parallel to and offset from said secondlongitudinal axis.
 8. The filter element assembly of claim 7, furtherincluding a sealing ring on said filter body around said axial outlet.9. The filter element assembly of claim 1, wherein a first end of saidcore is closed by said support and a second end of said core is an axialoutlet.
 10. The filter element assembly of claim 1, wherein said filterbody is a pleat-pack filter.
 11. The filter element assembly of claim 1,wherein said auxiliary filter is an open cell foam.
 12. The filterelement assembly of claim 1, wherein said auxiliary filter is carried onsaid support outside said core.
 13. The filter element assembly of claim1, wherein said filter body has a first longitudinal axis and saidauxiliary filter has a second longitudinal axis wherein said firstlongitudinal axis is parallel to and offset from said secondlongitudinal axis.
 14. The filter element assembly of claim 1, furtherincluding a sealing ring on said filter body around said axial outlet.15. The filter element assembly of claim 1, wherein said supportincludes a base and a cage, said filter body being received on said basearound said cage.
 16. The filter element assembly of claim 15, whereinsaid support further includes an auxiliary filter mount that receivedand holds said auxiliary filter.
 17. The filter element assembly orclaim 16, wherein said auxiliary filter mount includes two partitionsthat divide said filter body into a first section that functions as aprimary filter and a second section that is downstream from saidauxiliary filter.
 18. The filter element assembly of claim 17, whereinsaid filter body is a pleat-pack filter and said sections are receivedin two valleys between pleats.
 19. The filter element assembly of claim18, wherein said auxiliary filter includes a mounting groove and saidauxiliary filter mount includes a u-shaped wall received in saidmounting groove.
 20. The filter element assembly of claim 19, furtherincluding a fastener received in said two partitions and said mountinggroove to secure said auxiliary filter to said support.